Foldable container

ABSTRACT

A container has a first orientation and a second orientation. The container includes a frame assembly and a cover assembly. The frame assembly includes panel sections that have a spaced apart relationship in the first orientation and have a non-spaced apart relationship in the second orientation. The frame assembly further includes a wrap section that helps maintain the panel sections in the spaced apart relationship in the first orientation. The cover assembly is arranged and configured to fit over the frame assembly in the second orientation.

FIELD

[0001] The present disclosure relates to containers and, in particular, to containers having a first, unassembled orientation, and a second, assembled orientation.

BACKGROUND

[0002] Perishable foods and other temperature sensitive materials are typically packed in containers and the containers stacked in refrigerated locations for storage or shipment. These items can also be shipped in containers, such as coolers, to keep the items cool. Typically, these containers have fixed shapes and are assembled and stored prior to use. For example, U.S. Pat. Nos. 4,235,346; 4,903,859; 2,720,998; 3,552,466; 4,571,232; and 3,675,808 discuss various containers. The “Packaging Perishables” brochure by TechPak Solutions, included in the Information Disclosure Statement filed herewith, shows a sample of various types of cooler containers available on the market.

[0003] Because of the volume of existing containers, the cost of shipping the empty containers to customers is high. The number of containers that fit on a shipping pallet, and therefore the number of containers that can be fit in a semi trailer or flatcar is greatly limited. Similarly, because these containers are so large the amount of floor space necessary to store these containers increases and thereby increases the cost of storage. The present invention provides a container that lays flat during shipping and storage and yet can be readily assembled into a storage container when desired for shipping.

SUMMARY

[0004] In accordance with the present disclosure, the above and other problems are solved by the following:

[0005] In one aspect of the present disclosure, a container has a first orientation and a second orientation. The container includes a frame assembly and a cover assembly. The frame assembly includes panel sections that have a spaced apart relationship in the first orientation and have a non-spaced apart relationship in the second orientation. The frame assembly further includes a wrap section that helps maintain the panel sections in the spaced apart relationship in the first orientation. The cover assembly is arranged and configured to fit over the frame assembly in the second orientation.

[0006] In another aspect of the present disclosure, a container has a first orientation and a second orientation. The container includes a frame assembly, a cover assembly, and a box assembly. The frame assembly includes a first panel section, a second panel section, a third panel section, a fourth panel section, and a fifth panel section. The second, third, fourth, and fifth panel sections are arranged a spaced apart distance from the first panel section in the first orientation, and at a non-spaced apart relationship in the second orientation.

[0007] The frame assembly further includes a wrap section that helps maintain the panel sections at the spaced apart distance in the first orientation. The cover assembly is arranged and configured to fit over the frame assembly in the second orientation and to enclose the container. The box assembly receives the frame assembly and cover assembly for shipment.

[0008] In another aspect of the present disclosure, a method of assembling a container includes taking a frame assembly having panel sections arranged at a spaced apart distance in a first orientation from a stack of a plurality of frame assemblies; folding the frame assembly into a second orientation such that the panel sections are arranged at a non-spaced apart distance; and placing a cover over the frame assembly to enclose the inside of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and the advantages of the present disclosure are described more completely below in conjunction with the accompanying drawings in which like parts are identified by like numerals and wherein:

[0010]FIG. 1 is a perspective view of a container, in an assembled orientation, in accordance with the present disclosure.

[0011]FIG. 2 is a perspective view of the container of FIG. 1, in an unassembled orientation, in accordance with the present disclosure.

[0012]FIG. 3 is a perspective view of the container of FIG. 1, in a partially assembled orientation, in accordance with the present disclosure.

DETAILED DESCRIPTION

[0013] In general, the present disclosure relates to containers that are stackable in an unassembled orientation for easy storage, and that can be assembled quickly and easily just before shipment. Preferably, the container lies relatively flat, while unassembled. The container can then be assembled, or folded together and placed inside a box for shipment.

[0014] The present disclosure has numerous advantages over known containers. One such advantage is that the container of the present disclosure is relatively flat in a first, unassembled, orientation and thus is easily stackable and storable. Another such advantage is that the container of the present disclosure is relatively inexpensive. Yet another advantage is that the container of the present disclosure is easily assembled from a first orientation to a second, assembled orientation.

[0015] Referring to FIG. 1, a container 100 is illustrated. In general, the container 100 includes a frame assembly 110 and a closer assembly 120. The container 100 can then be placed inside a box 140, such as a cardboard box of a known, conventional type. In the particular example illustrated, the box 140 is just slightly larger than the container 100, such that the container 100 fits snuggly or tightly within the box 140.

[0016] Referring to FIG. 2, the frame assembly 110 of the container 100 is shown in a first, unassembled orientation. In this first orientation, the frame assembly 110 lies relatively flat and a plurality of frame assemblies 110 can be stacked on top of each other for easy storage.

[0017] Preferably, the frame assembly 110 includes a plurality of panel sections 150. Generally, the panel sections 150 comprise an insulating material, such as polystyrene, Expandable Polystyrene (EPS), or a polymer material. The insulating material serves to help maintain the inside of the container 100 within a desired temperature range. Preferably, the panel sections 150 comprise polystyrene. Of course, any suitable material can be used.

[0018] The panel sections 150 can have any suitable size or shape configuration. Typically, the panel sections 150 will have a thickness t corresponding to a commonly available thickness of the material being used. Preferably, the thickness t is between 0.125 inches and 2 inches, and typically the thickness t is 0.75 inches.

[0019] The panel sections 150 include a first panel 152, a second panel 154, a third panel 156, a fourth panel 158, and a fifth panel 159. Typically, the first panel 152 is a bottom panel 162. The second panel 154 and third panel 156 are first side panel 164 and second side panel 166. The fourth panel 158 and fifth panel 159 are first end panel 168 and second end panel 169.

[0020] In the unassembled orientation illustrated in FIG. 2, the panel sections 150 are configured and arranged as illustrated. The bottom panel 152 has a first side edge 170, a second side edge 171, a first end edge 172, and a second end edge 173. In general, the bottom panel 162 is arranged in the middle of the frame assembly as shown. The first side panel 154 has a first side edge 174. The first side panel 154 is arranged as illustrated at a spaced apart distance X from the bottom panel 162 such that the first side edge 174 is adjacent the first side edge 170 of the bottom panel 162 at the spaced apart distance X. The spaced apart distance X is approximately equal to the thickness t of the panel sections 150.

[0021] Likewise, the second side panel 156 has a first side edge 175. The second side panel 156 is arranged as illustrated at the spaced apart distance X from the bottom panel 162 such that the first side edge 175 is adjacent the second side edge 171 of the bottom panel 162 at the spaced apart distance X.

[0022] The first end panel 158 has a first end edge 176. The first end panel 158 is arranged as illustrated at the spaced apart distance X from the bottom panel 162 such that the first end edge 176 is adjacent the first end edge 172 of the bottom panel 162 at the spaced apart distance X.

[0023] Likewise, the second end panel 159 has a first end edge 177. The second end panel 159 is arranged as illustrated at the spaced apart distance X from the bottom panel 162 such that the first end edge 177 is adjacent the second end edge 173 of the bottom panel 162 at the spaced apart distance X.

[0024] The frame assembly 120 also includes a wrap section 180. Preferably, the wrap section 180 is comprised of a pliable material, such as plastic. Of course, any suitable material can be used. The panel sections 150 are placed on the wrap section 180. Preferably, the panel sections 150 are attached to the wrap section 180, such as by an adhesive or some other suitable form of attachment. The wrap section 180 helps maintain the panel section layout described above and illustrated in FIG. 2. The wrap section 180 also maintains the spaced apart relationship of the panel sections for later assembly.

[0025] The frame assembly 100 can be stored in the configuration illustrated in FIG. 2. Multiple frame assemblies 100 can be stacked on top of one another for ease of storage. This orientation facilitates storage of the container 100.

[0026] Referring to FIG. 3, the frame assembly is illustrated in a partially assembly orientation. During use, a frame assembly 110 is taken from storage as arranged and configured in FIG. 2. The frame assembly 110 will now be assembled into a cube-like orientation for use. The bottom panel 162 remains in its unassembled orientation. The first side panel 164 is lifted up to a ninety (90) degree orientation with respect to the bottom panel 162, such that the first side edge 174 of the first side panel 164 touches the first side edge 170 of the bottom panel 162 at a non-spaced apart, or adjacent, distance.

[0027] Likewise, the second side panel 166 is lifted up to a ninety (90) degree orientation with respect to the bottom panel 162, such that the second side edge 175 of the second side panel 166 touches the second side edge 171 of the bottom panel 162 at a non-spaced apart, or adjacent, distance.

[0028] The first end panel 168 is lifted up to a ninety (90) degree orientation with respect to the bottom panel 162, such that the first end edge 176 of the first end panel 168 touches the first end edge 172 of the bottom panel 162 at a non-spaced apart, or adjacent, distance. Likewise, the second end panel 169 is lifted up to a ninety (90) degree orientation with respect to the bottom panel 162, such that the second end edge 177 of the second end panel 169 touches the second end edge 173 of the bottom panel 162 at a non-spaced apart, or adjacent distance.

[0029] In this fashion, the container is assembled from the first, unassembled orientation illustrated in FIG. 2, through a partially assembled orientation illustrated in FIG. 3, to the second, assembled orientation illustrated in FIG. 1. The second, assembled orientation illustrated in FIG. 1 is similar to a cube-like orientation of a standard box or Styrofoam cooler.

[0030] Referring to FIG. 1, in the second, assembled orientation, the wrap section 180 will have extra material 182 that is simply folded to one side or another of the second, assembled orientation. The wrap section 180 helps to retain moisture within the frame assembly 110. The frame assembly 110 can then be inserted into a standard box 140.

[0031] The cover assembly 120 includes a top 121. Preferably, the top 121 comprises an insulating material, such as polystyrene or a polymer material. The insulating material serves to help maintain the inside of the container 100 within a desired temperature range. Preferably, the top 121 comprises polystyrene. Of course, any suitable material can be used. A plurality of tops 121 can be stacked on top of one another for storage, similar to the frame assemblies 110.

[0032] During use, the frame assembly 110 is assembled from its first, un assembled orientation into the second, assembled orientation. The extra material 182 of the wrap section 180 is folded to one side or another of the frame assembly 110. The frame assembly 110 is then placed in a conventional box 140. Contents can then be placed within the frame assembly 110. Typically, a cooling device (not shown), such as a frozen gel pack, or dry ice, will be placed into the frame assembly 110 with the contents to help maintain a desired temperature range. The top 121 is then placed on the frame assembly 110, and the box is closed.

[0033] Although specific embodiments of the present invention have been described and illustrated, it will be appreciated by those skilled in the art that many variations of the designs described can be practiced within the scope of the present disclosure, and that all such variations are contemplated within the teaching of the present disclosure. Accordingly, the scope of the disclosure is not limited to the specific embodiments shown, but is limited only by the scope of the following claims. 

1. A container having a first orientation and a second orientation, the container comprising: a frame assembly including panel sections having a spaced apart relationship in the first orientation, and having a non-spaced apart relationship in the second orientation, the frame assembly further including a wrap section that helps maintain the panel sections in the spaced apart relationship in the first orientation; and a cover assembly arranged and configured to fit over the frame assembly in the second orientation.
 2. A container according to claim 1 wherein the panel sections include a first panel section, a second panel section, a third panel section, a fourth panel section, and a fifth panel section.
 3. A container according to claim 1 wherein the panel sections have a thickness between 0.25 inches and 2 inches.
 4. A container according to claim 1 wherein the panel sections have a thickness approximately equal to a spaced apart distance.
 5. A container according to claim 1 wherein the panel sections comprise a polystyrene material.
 6. A container according to claim 1 wherein the wrap section comprises a polymer material.
 7. A container according to claim 1, further including a box assembly for reception of the frame assembly and cover assembly.
 8. A container having a first orientation and a second orientation, the container comprising: a frame assembly including a first panel section, a second panel section, a third panel section, a fourth panel section, and a fifth panel section, the second, third, fourth, and fifth panel sections being arranged a spaced apart distance from the first panel section in the first orientation, and at a non-spaced apart relationship in the second orientation, the frame assembly further including a wrap section that helps maintain the panel sections at the spaced apart distance in the first orientation; a cover assembly arranged and configured to fit over the frame assembly in the second orientation and to enclose the container; and a box assembly for reception of the frame assembly and cover assembly for shipment.
 9. A container according to claim 8 wherein the panel sections have a thickness between 0.25 inches and 2 inches.
 10. A container according to claim 8 wherein the panel sections have a thickness approximately equal to the spaced apart distance.
 11. A container according to claim 8 wherein the panel sections comprise a polystyrene material.
 12. A container according to claim 8 wherein the wrap section comprises a polymer material.
 13. A method of assembling a container, the method comprising: taking a frame assembly having panel sections arranged at a spaced apart distance in a first orientation from a stack of a plurality of frame assemblies; and folding the frame assembly into a second orientation such that the panel sections are arranged at a non-spaced apart distance; placing a cover over the frame assembly to enclose the inside of the container.
 14. A method according to claim 13, further comprising: placing the frame assembly into a box for shipment.
 15. A method according to claim 13, further comprising: folding extra material of the frame assembly. 